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Update: Specification for Anodized Aluminum and its Alloys (MIL-A-8625F)

Mark Jozefowicz, Reliant Aluminum Products, LLC

The Aluminum Anodizers Council was alerted to an issue regarding MIL-A-8625F specification for anodized aluminum, a specification that has been in use for more than 25 years. The update to the specification disallows the use of nickel acetate/surfactant seal chemistry, a process that is used by most anodizers. In response, AAC is working with the specification holder to amend the clause. We expect to see the new specification in the coming weeks. In the meantime, AAC is currently in the process of developing a specification that covers the requirements for two types and two classes of anodized aluminum coatings for non-architectural applications, which is the non-military equivalent of MIL-A-8625. Learn the latest information on this important issue from Mark Jozefowicz who is spearheading the process.

What’s Next For Aluminum in Automotive

Gregg Peterson, Michigan Manufacturing Technology Center

The emerging consensus is that your next car is likely to be a multi-material vehicle with a mix of advanced high strength steel, aluminum, magnesium and perhaps composites.And it will be assembled less by traditional spot welds and more by structural adhesives.So what does this mean for extruders and anodizers?What specific applications appear most attractive, and what will be required to capture them?How can extruders and anodizers better meet the challenges the OEMs and Tier 1's would like addressed, and by doing so, help themselves? Gregg Peterson, Principle Materials Engineer at the MMTC will provide some insight.

Anodizing Aluminum for Precision Medicine: The Future of Healthcare

Matthew Nickel, University of Alberta

Precision medicine is health care tailored to the individual and is the future of medicine under the U.S. Precision Medicine Initiative. One of the pitfalls with personalized medical care is that it benefits far too few patients for the dollars spent. Visual diagnostics based on anodized aluminum may be a cost-effective solution. The health of an individual may be assessed by visualizing a surface color change. We demonstrate the ability to detect color shifts from molecules as small as 2nm at pmolar concentrations on the anodized surface. It was used to detect biomarkers of the measles virus.

Ammonia & U.S. EPA Regulations

Janette Courtney, Bonnell Aluminum

Ammonia is a byproduct from the aluminum acid etch and aluminum anodizing processes. The U.S. Environmental Protection Agency has regulations regarding ammonia. This presentation will cover the Clean Water Act and Clean Air Act and how they pertain to ammonia. Case studies will be presented.

Acid Etch: Options for Ammonia

Linda Newman, Houghton International

Acid etch is known for hiding many extrusion defects and producing a very smooth matte finish. One challenge acid etch users face is dealing with ammonia in wastewater. This presentation will discuss what ammonia levels to expect from acid etch and ways to reduce ammonia in wastewater.

Importance of the Anodize Process in Regards to Sporting Goods Shelf Appeal and Quality

Vance Jones, Easton Technical Products

This paper will discuss the importance of how consistency of the anodized coating plays a key role in the quality of sporting goods.Using Statistical Process Control to monitor critical parameters, how the cosmetics of sporting goods are important for shelf appeal and what has been done to insure color consistency will be discussed. Several case examples will be shared and several products will be covered including arrow shafts, tent tubing, mountain climbing and fishing equipment.

Considerations for Matching Anodized Components

Jude M. Runge, Ph.D., CompCote International, Inc.

There are many reasons why aluminum alloys are selected for recreational products: they are lightweight and strong, with high impact resistance and fatigue strength. It is also clear why anodizing is often the finish of choice: It looks good, and is, by far, the lightest-weight finish; the same aluminum alloy bike frame, when painted, weighs 200 - 300g more than the same frame anodized. To optimize the appearance of assemblies with multiple anodized components, it is necessary that they have the same color and appearance. This paper presents, with the aid of a case study, some of the challenges and solutions with matching anodized and dyed components specifically used for bicycles manufactured with 7000-series aluminum components.

Anodizing Armament/Gun Components – Anodizing Factors and Features to Consider in the Anodizing Finish

Tej Patel, Techevon LLC

This paper will provide an overview of the anodizing industry as it relates to armament components and end user expectations for color, finish, uniformity and durability. Specifically factors such as mechanical pretreatment and subsequent chemical pretreatments prior to anodizing will be discussed. Furthermore, the paper will provide information on how to address galvanic corrosion as it relates to alloys, tooling, dye chemistry and other operations.

Anodizing of Brake Calipers

Stefan Lenzer, MacDermid Enthone

The market share of brake components made of aluminum and the quality requirements for components of automotive braking systems are increasing, both with regard to functionally relevant parameters—essential for system reliability—as well as corrosion protection and decorative properties. Due to the aluminum alloy composition of brake components, the anodization has special demands on the coater and therefore on the process suppliers. This presentation provides an overview of the requirements and specifications for anodized aluminum calipers in the automotive industry. Furthermore, the relevant processes are considered, taking into account the aluminum alloys and quality requirements.

This session will address a variety of dye topics, including a brief history of dyes covering synthetic and natural dyes, what they are and where they come from, and dye classes. In addition, Azo Dyes and how they are made will be discussed. Characteristics that make dyes good for anodizing, and dyes and the anodic surface will be covered. And, finally, the author will share his thoughts on the future of dyes.

Integral Coloring in the Color and Dye Technology

Marcello Rossi, Italtecno Srl

It is possible to get uniform color anodizing using special type of new rectifiers with pulses at variable frequency. The use of the new generation of rectifier allows to obtain harder coating layers and colors from bronze to black directly in the anodizing tank with the use of special new generation non-toxic electrolytes. The colors may also depend on the composition of the alloys. The new generation of rectifiers allows to get more uniform color with lower energy consumption in comparison to the conventional ways to obtain integral coloring of many decades ago.

Dyeing and Light Fastness of Aluminum Anodizing

Kenji Hara, Okuno Chemical Industries Co., LTD

Aluminum anodizing can be finished in various color tones without damaging metal texture by dyeing. For this reason, dyeing of aluminum anodizing is also used for electronic equipment such as digital camera exterior and smartphone housing which requires the design. In this presentation, dyeing and light fastness of aluminum anodizing are presented. Regarding the dyeing of aluminum anodizing, the influence of the conditions in surface conditioning and in dyeing on dyeability will be explained. Furthermore, the results of investigating the dye penetration of aluminum anodizing by GD-OES is discussed. Also, we explain the light fastness of the dyeing product of aluminum anodizing. We propose several methods to improve light fastness, which is a problem of dyeing of aluminum anodizing.

Selecting a Black Dye for Your Application

Pinakin Patel, Techevon LLC

This paper will discuss the varying degrees of industry preferences on determining a black dye. A number of factors such as undertone, heat/light fastness, metamerism, and other chemistry aspects will be presented in order to educate anodizers on the newest trends in black dyes within the anodizing field. It will also discuss the effect of coating thickness/density on color depth as well as the effects of contaminants such as aluminum sulfates and aluminum phosphates.

Practical additions have been overlooked and not made properly by numerous anodize facilities. This paper will present the real importance of practical additions as they are related to quality and efficiency issues. Discussions will include: 1) How and when practical additions should be made including follow up analyses, 2) The significance of free and total sulfuric acid concentrations in the anodize tank, including aluminum build up and drag out, and 3) The use of Anodize Test Evaluation Cells (ATEC) for making practical additions of additives, modifiers and/or accelerators.

The Environmentally Friendly Bright Finish for Aluminum

Wayne Chandler, SIC Technologies, Inc.

The history of electro-polishing from the early 1930’s to current day is discussed in addition to the method of processing and the effects of different variables on the metal. Comparison with chemical bright dipping is also discussed. The advantages and disadvantages of electro-polishing are delineated.

The Effect of Dissolved Aluminum in Low Caustic Etch Baths Used as Post Treatment on Acid Etched Surfaces

Can Akyil, Politenik

This paper aims to find the optimum range for the dissolved aluminum in low caustic concentration baths as post treatment after acid etch process, to achieve the desired surface effect with minimum deviations from the set values such as surface gloss and the color shade. To investigate the effect of dissolved aluminum on the surface morphology in low caustic etching baths; SEM/SEI investigations, 3D surface profiling, surface gloss measurements and spectrophotometer analyses used.

Deoxidizing Aluminum and its Effectiveness as a Pre-Treatment for Anodizing Aluminum Alloys

Peter Totaro, Master Metal Finishers

Deoxidizing solutions are widely used as a subsequent treatment after etching aluminum. However, the inherent properties of deoxidizing solutions allow for a wide range of applications from enhancing the activity of the substrate to removing chemical film. This lecture will delve into the basic mechanisms of deoxidizer chemistry, what applications deoxidizer solutions can be used for and solution maintenance for these applications. This is a comprehensive view of all roles that deoxidizer solutions can be used in plating.

Our B&C Team is currently completing a research study designed to provide a contemporary view of market dynamics for commercial building and potential strategies with key influencers and decision makers.Dr. Ujjval Vyas, principal of the Alberti Group and the research lead, will share the findings.

From Chemistry to Components:Our Message to Automotive Engineers

AEC Automotive Team Members

Aluminum extrusions continue to expand their role in the automotive market.From 2012 through 2016 per vehicle use of extruded shapes increased by over 50%, and all indications are for continued growth.

With this expansion, the challenge of marketing to the auto market is also growing.Yes, our messages about alloy and geometry are still relevant to the many new automotive engineers and designers who lack extrusion exposure,But there is a growing cadre of more experienced engineers who are specifying microstructure of the final component as they seek to realize higher performance.

Our Auto Team has been retooling its materials and messaging to better engage these more demanding specifiers.Hear the results.

LIFTing Extrusion

Gregg Peterson, Michigan Manufacturing Technology Center

Lightweight Innovations for Tomorrow – or LIFT -- is a Detroit-based public/private partnership to create a bridge between metals-related research and production ready processes for transportation lightweighting.

With their own brand new 6” Danielli press, robotic assembly station, and metallurgical lab they can offer a wide range of development capabilities to extruders.

Equally important, their extensive workforce development program is developing the workforce to design, program and operate the coming processes - targeting community colleges and high schools as well as colleges & universities throughout the Midwest.

Learn all about LIFT, and how your company can capitalize on this impressive new asset.

Keep Aluminum Windows (KAW) Update

Thomas Culp, Birchpoint Consulting

This session will focus on the most recent changes in energy and green construction codes that impact the aluminum extrusion industry. Codes, standards, and programs such as ASHRAE 90.1, ASHRAE 189.1, International Energy Conservation Code (IECC), International Green Construction Code (IgCC), LEED, and NFRC directly affect AEC members and their customers who supply commercial window, curtain wall, door, shading, and photovoltaic panel products to the architectural market. We will discuss the impact of the latest changes, as well as future directions and recent innovations in framing and glazing technology that could influence planning for AEC members. Back to top

David Spooner with Barnes & Thornburg LLP will return to update on the latest issues involving the Curtain Wall scope case. We expect direction from the newly appointed judge by this September. So, we plan to discuss our next steps in this case.

232 Investigation Update

Jeff Henderson, Aluminum Extruders Council

The ongoing U.S. 232 Investigation into the national security implications of imported aluminum will be covered. This initiative by the Trump Administration presents both opportunities and threats for our industry. We will use this time to discuss our progress and the next steps. This session is open to AEC Extruder Members only; no media.

AEC Fair Trade – The Way Forward

Jeff Henderson, Aluminum Extruders Council

In our last Fair Trade session of the afternoon, we will discuss the options available to the AEC as a result of decisions we expect to receive from the administration by September. These may include trade enforcement, scope challenges, 232 & 332 Investigation implications, and many other topics. Back to top

The session will outline the approach utilized by EnPro Industries in becoming One of America’s Safest Companies. Through a unique approach, EnPro has been successful in implementing a robust system driven by a culture of Caring, Sharing and Learning within the work place. This session will explore this approach and how can be utilized to address all key aspects of a robust safety system including Management Commitment, Safety Leadership, Individual habits and behaviors and Cultural Development.

Succession Planning Workshop

Duncan Crowdis, Alexandria Industries

Many of us who look around at our leadership teams or in our Board Rooms realize that in the next 5 to 10 years there will most definitely be a shift in personnel whether we want it or not. The question is “Is your business ready"? In our day-to-day priorities we often serve the URGENT at the expense of the IMPORTANT. Work and reflection related to succession planning often takes a back seat. While this is certainly understandable, most of us have worked too hard and feel too attached to the success of our business to allow it to fade away due to a lack of planning for the future. In this interactive workshop, we will explore the various areas and levels of succession planning and how it can be done without the bureaucracy that accompanies many Succession Planning tools.

AEC Survey: Making Data More Relevant

Andy Curland, Vitex Corp.

The Surveys & Reports Team revised the Key Indicator Survey, removing redundant questions covered in other surveys and drilling deeper into press data, thus creating a much more focused, relevant study of press performance through the new Press Performance Benchmarking Study. Team Leader Andy Curland will show you how much more valuable this reported data can be in measuring your own press performance.

The Significance of Mandrel Bearing Undercut (shear edge) for Productivity and Shape Control in Hollow Dies

An encore of a webinar presented last April, this session will explore the effects of the mandrel undercut (shear edge) on metal flow, die pressure (ease of push) and on die deflection/strength. Design guidelines will be developed for the use of undercut to optimize the effect on productivity, profile shape and die face pressure. Manufacturing guidelines will also be developed to ensure that die life is not adversely impacted by the application of large mandrel undercuts.

In her capacity as Editorial Director, Metals Pricing and Market Engagement, Karen McBeth oversees Platts’ global price assessing and development of price indices for the ferrous and nonferrous markets. Much has happened in the aluminum industry since Ms. McBeth spoke at last fall’s Management Conference. She will return to give us her latest insights into the aluminum industry and what it all means for 2018. Extruders will find this information very valuable as they determine their metal needs for next year.

Take 5 Presentations

In this popular segment, select AEC Supplier Members will each take five minutes to brief fellow members on the latest services, equipment and technologies for the extrusion industry.

Keynote Address: Grit in the Face of Seemingly Insurmountable Odds

Scott O'Grady

As an Air Force fighter pilot, Captain Scott O’Grady was shot down over Bosnia while helping to enforce the NATO no-fly zone in an F-16. Alone—facing death, capture and the elements—he discovered within himself the spirit to go on and relied on the skills learned during a lifetime of preparing for the unthinkable. From O’Grady’s compelling life-and-death story, attendees will learn how to adapt, change and succeed even under the most daunting and trying of circumstances.